Machine For Inspecting Glass Containers At An Inspection Station Using An Addition Of A Plurality Of Illuminations Of Reflected Light

ABSTRACT

A machine for inspecting glass containers which are being rotated at an inspection station. A light source illuminates a selected area on a rotating glass container while the container rotates through a selected angle and a camera is triggered to capture an image while the bottle rotates through that angle. A plurality of sequential images are recorded and a critical addition is made to be inspected.

CROSS REFERENCE TO RELATED APPLICATIONS

This patent application is a divisional patent application of copending U.S. patent application Ser. No. 11/585,388, filed on Oct. 23, 2006, entitled “Machine For Inspecting Glass Containers At An Inspection Station Using An Addition Of A Plurality Of Illuminations Of Reflected Light,” which patent application is assigned to the assignees of the present invention and which is hereby incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to machines, which inspect glass containers for defects, and more particularly, to a system which inspects for cracks in translucent glass containers.

In the glass container industry, small cracks or fracture in the glass are referred to as “check defects. Checks can range from sub millimeters to several hundred millimeters and can be oriented at any direction from vertical to horizontal. Glass is not a crystalline structure by nature, but most cracks propagate roughly along a plane of some orientation in space mostly determined by the shape of the glass at that location. For example, a crack that began as a vertical crack at the upper surface of the mouth primarily propagates in a vertical plane. Checks can appear in any orientation and on any portion of a container and can exist wholly within the glass or may penetrate to one or both surfaces. Checks are considered phase objects and do not absorb light like a solid objects does. Checks are primarily reflective in nature if their opposed surface separation is at least half a wavelength of light. However, very few checks with a smaller separation will reflect light and accordingly they will not likely be detectable by direct reflection methods, but they might have scattering points when they penetrate to the one or both surfaces of the container and will scatter light back to the sensors.

Most of these crack defects will drastically weaken the bottle, often causing it to rupture or to leak. Therefore, bottle manufacturers like to remove these containers before they reach filling plants. Checks appearing near the mouth of the containers are called finish checks. In the glass bottle industry, the term “container finish” refers to the portion of the bottle that defines the mouth, threads or beads, and the ring. The upper surface of the mouth is referred as the sealing surface.

Almost all commercially available check detectors work on the principle of reflected light. A conventional check detector consists of a series of continuously operating light spot light sources and associated photodetectors that are positioned so that known checks on a bottle rotating at an inspection station will reflect light from one of the sources to one of the photo-detectors. Signal processing of the photodetector outputs recovers the sharp peaks while rejecting lower frequency signal variations caused by ambient light, reflection from the bottle sidewall, etc.

While commercially available check detectors are successfully deployed on most glass bottle production lines, there are several drawbacks to the approach. A few of those are: many point sensors are required for many possible reflection angles; some sensor angles are difficult to position; additional sensors and lights need to be added as more production defects appear; time consuming setup is required for each type of container; and the difficulty of reproducing the same setup from one inspection line to another.

The following U.S. Pat. Nos. 4,701,612, to Sturgill; 4,945,228, to Juvinall et al.; 4,958,223, to Juvinall et al.; 5,020,908, to Hermann; 5,200,801, to Juvinall et al.; 5,895,911, to Giometti et al.; 6,104,482, to Brower et al.; 6,211,952, to Weiland et al.; and 6,275,287, to Watanabe all relate to devices that detect defects in the finish of a container.

SUMMARY OF THE INVENTION

The present invention provides an apparatus for inspecting glass containers, which can detect vertical, horizontal, and any other angle cracks on a bottle which is user friendly and easily adjusted. It also provides a detector that can detect known types of checks and also any new checks without specific setup requirements.

DESCRIPTION OF THE DRAWINGS

The present invention is illustrated in the following accompanying drawings which illustrate, in accordance with the mandate of the patent statutes, a presently preferred embodiment incorporating the principles of the invention.

FIG. 1 is an oblique elevational schematic view of an inspection station of a machine for inspecting glass containers for checks and other defects, made in accordance with the teachings of the present invention;

FIG. 2 is a block diagram showing the operation of the pairs of light sources and camera shown in FIG. 1;

FIG. 3 is a schematic top view of the container at the inspection station showing the light axes of a pair of light sources and the camera;

FIG. 4 is a schematic elevational view showing the light axes of the light sources and camera shown in FIG. 3;

FIG. 5 is a logic diagram illustrating the operation of the camera system of the inspection machine;

FIG. 6 is a logic diagram illustrating the operation of the lighting system of the inspection machine;

FIG. 7 is a timing diagram illustrating the operation of the light sources;

FIG. 8 is a side elevational view of one of the light sources; and

FIG. 9 is an elevational view showing how the LED's of one of the light sources are aimed toward the finish.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT

In a machine for inspecting glass containers (bottles), the containers 10 are transported along a conveyor 12 to an inspection station illustrated in FIG. 1. The conveyor may be a linear belt or a turret type feed system. A container 10 is engaged by upper and lower rear pairs of idler rollers 14 and a front drive wheel 16 so that rotation of the drive wheel in the clockwise direction will rotate the container in the counterclockwise direction. There is conveyor dwell of sufficient duration at the inspection machine so that the container can be rotated more than 360 degrees while the inspection takes place. A container present sensor 18 will sense the presence of a container at the inspection station (the sensor can be upstream and the actual presence of the container at the inspection station could be defined by an encoder count following the sensing of the container by the upstream part present sensor. Light sources (Light Source #1/20 (see FIGS. 1 and 2) and Light Source #2/21) illuminate the finish portion of the container and a Camera/22 images the finish portion.

FIG. 2 illustrates the operation of the Camera and Light Sources. A Computer 24 delivers On/Off signals to Light Source #1/20 and Light Source #2/21 and delivers Camera Trigger signals to the Camera/22. The Camera has a matrix array of elements (pixels) to receive an image of the finish portion of the container during the Camera's exposure period. The Camera could be a CCD, MOS or like camera which will store an image until the next Trigger Signal. When a Trigger Signal is received, the existing image will be captured and transferred, as an “Acquisition,” to the Computer so that it can be recorded and processed by the Computer. The Computer will issue a Reject Signal if a defect is identified.

As can be seen from FIGS. 3 and 4, the Light Axis for each light source, which is in the positive “Z” plane of the container, is horizontal and intersects the axis “A” of the container. The two light axes are orthogonal to each other and 45° to a vertical plane including the Camera Detector Axis. The Detector Axis for the Camera/22, which is located in the negative “Z” plane, is approximately 45° from horizontal. With this relationship, the camera is looking at a dark field and seeing only light coming from the checks. The light sources and camera are supported by structure 28 that can be vertically displaced and horizontally displaced to reposition the system for different height/diameter containers.

To start an inspection, the machine will Transfer A Bottle To The Inspection Station/30. Following a time sufficient for the rotation of the bottle, by the drive wheel, to become stable, the Computer will Trigger The Camera/32. This starts the acquisition of the image. The following explanation is provided in terms of angles for purposes of clarity, but it should be understood that in a digitally controlled camera, instructions may be time based rather than defining actual angles so that when something is to occur in an approximate θ° (60° angle in the preferred embodiment), an approximate time (number of pulses) may be selected which approximately corresponds to that angle and where events are desired approximately every 7.5°, for example, the pulses could be divided by 8. When the query “Has Bottle Rotated θ° ?”/34 (θ° or a selected number of pulses corresponding approximately to that angle of rotation can be set) is answered in the affirmative, the Computer will Transfer And Record The Acquisition/36. Once the Camera is triggered, the Camera will capture data until the Camera is again triggered (following the rotation through θ°). When the Computer answers the query “Y Acquisitions?” in the negative, the Computer will again Trigger The Camera/32. When the computer answers the query “Y Acquisitions?”/38 in the affirmative (“Y’ may be set and is six in the preferred embodiment), the Computer will Create An Image From Y Acquisitions To be Analyzed/40. The image created (a Critical Addition), where as in the preferred embodiment “Y” is six, will represent the entire (approximately) 3600 surface of the finish and will be the Critical Addition of six acquisitions each imaging eight illuminations.

The critical addition will be made in a manner that will maximize the data that indicates that a defect is present. The Critical Addition can represent for each pixel location, the highest intensity of the corresponding pixel in all six Acquisitions which will make up the Critical Addition. Then, when the Computer answers the inquiry Next Bottle?/44 in the affirmative, the next bottle can be processed.

An image processing technique may be used to enhance the signal created by checks from signal created by mold features of the container. First, a reference or “mask image,” can be created using a set of sample containers without defects running through the inspection setup (containers without defects are referred as “good ware” and containers with defects that need to be removed during the inspection as “bad ware”). To incorporate all the signals created by good ware from different molds that may contain slightly different structural variations, and small variations of signals due to vibrations and rotation, a large number of images can be acquired and processed to create the mask image. These images contain almost all the possible variation of light reflection by mold marks, threads, seams, and curved surface of good ware. Mask image is created by combining the all the good ware images. A mask image is created and is compared with the reference mask created with good ware. The difference between the image and the mask shows the signals created by check defects.

FIG. 6 illustrates the operation of the light sources. When the Computer answers the query “Is Image Acquisition To Begin?”/52 in the affirmative, the Computer will Turn Lights “On” For Angle “α”/54 (“α” may be set and could be a defined number of pulses). When the Computer answers the query “Has Container Rotated “φ°”/56 in the affirmative (φ can be set), and answers the query “Has Container Rotated θ° ?”/58 in the negative, the light sources will again be turned “on.” When this inquiry is answered in the affirmative (θ/φ pulse per acquisition), and the query Have “Y” Images Been Acquired?/60,” in the negative the entire surface has not been imaged and the entire process can be repeated until “Y” images have been acquired (Y pulses per acquisition). Then, when the computer answers the inquiry “Has Next Container Been Sensed?”/62 in the affirmative, the entire process can be repeated for the next bottle. If the lights are to be on for the entire time that the camera is triggered (α can be set to equal θ°).

To reduce noise, α is, in the preferred embodiment, defined so that the surface will be illuminated a small portion (25%) of the angle φ°. Checks that will cause a container to be rejected have been found to be imaged when the light sources are “on” only a small fraction of a. This fraction can be empirically varied to achieve a desired result. While the imaging process has been disclosed with reference to checks in the finish area of the container, it can be used to identify body or heel checks and other defects.

FIG. 7 is a timing diagram for an Acquisition comprised of light sources turned on  degrees for every φ° (7.5° in the preferred embodiment) through θ (60° in the preferred embodiment). The lower the ratio of α/φ°, the less noise will be available to interfere with the desired signal.

The light sources 70 (FIGS. 8 and 9) are mirror images and are segments of an arc. As shown the light source, mounted on a flat panel 71, is perpendicular to the Light Axis and faces the finish of the container 10 which is shown in dotted lines.

The segment has inner and outer (or three or four, . . . ) rows of LED's 72 with the central LED's 74, which define the Light Axis, standing parallel to the Light Axis and with the remaining LED's being progressively tilted toward the light axis as they proceed away from the Light Axis. The preferred location of the Light Axis is at the sealing surface 74 but it can be located from the sealing surface to the bottom of the finish. The ideal geometry that the preferred embodiment attempts to approach is that of conical illumination, where the top and bottom of the cone are dark so that the camera will not see any direct reflections of light. Viewing the finish as a torus, this conical geometry allows the maximum light to be projected onto the finish with direct reflection. Only an anomaly in the finish (a check) will generate direct reflections to the camera.

This apparatus has following advantages: because the area sensor image an area of the bottle, it is possible to detect almost all the checks in that region. This make the inspection is independent of the specific orientation and location of the check, and thus enable detecting “new” checks without changing the setup. The positioning of the area array sensors and light sources would not depend essentially on the geometry of the bottle. It will be easier to setup for most of the containers with little or no adjustments.

Although the foregoing description of the present invention has been shown and described with reference to particular embodiments and applications thereof, it has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the particular embodiments and applications disclosed. It will be apparent to those having ordinary skill in the art that a number of changes, modifications, variations, or alterations to the invention as described herein may be made, none of which depart from the spirit or scope of the present invention. The particular embodiments and applications were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such changes, modifications, variations, and alterations should therefore be seen as being within the scope of the present invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled. 

1. A method for inspecting a glass container for defects at an inspection station comprising: rotating a selected glass container about a vertical axis at the inspection station; illuminating a selected portion of the glass container with first and second light sources so that defects will be highlighted during the rotation of the glass container, the light sources having a selected illuminated on time followed by a selected off time, wherein the container rotates through a defined angle of rotation while the two light sources are successively on and off; turning said light sources on and off a plurality of consecutive times defining a plurality of illuminations during the defined angle of rotation, the plurality of illuminations equal to the number of times the light sources are turned on and off; imaging the selected illuminated portion of the glass container with a camera including a triggerable imaging portion and including a detector axis inclined to the horizontal, said camera having an exposure time at least equal to the time required for the glass container to rotate through said defined angle of rotation; and triggering the imaging portion of said camera with a computer when the container is at the beginning and end of said defined angle of rotation so that the camera will continuously acquire data of said selected portion of the container, as the glass container rotates through the defined angle of rotation to capture, transfer, and record each image when the imaging portion is triggered at the beginning and end of said defined angle of rotation, and to perform an addition of a plurality of recorded images, each including the plurality of illuminations for inspection for defects.
 2. A method according to claim 1, wherein the selected portion is the finish portion of the glass container.
 3. A method according to claim 2, wherein the defect is a check.
 4. A method according to claim 1, wherein said angle of rotation is a portion of 360 degrees.
 5. A method according to claim 1, wherein said light sources comprises a pair of orthogonal related LED panels.
 6. A method according to claim 4, wherein said light source comprises a pair of orthogonal related LED panels.
 7. A method according to claim 1, wherein the computer is configured to define a critical addition of the plurality (Y) of recorded images, within a corresponding plurality of said defined angles (0).
 8. A method according to claim 7, wherein the imaging portion of the camera comprises a matrix array of pixels which receives an image of the selected portion of the container, and wherein the critical addition includes, for each pixel location of the matrix array, the highest intensity of the corresponding pixel in all (Y) recorded images within the plurality of said defined angles (θ).
 9. A method for inspecting a glass container for defects using a light source and a camera, both controlled by a computer, the method comprising: rotating the glass container; illuminating a select portion of the glass container with energy from the light source; triggering the camera open at the beginning of a select angle of rotation of the glass container; capturing image data of the select portion of the glass container throughout the angle of rotation to create an image; and triggering the camera closed at the end of the select angle of rotation of the glass container, wherein a critical addition of the image data is analyzed in the computer to identify a defect in the glass container.
 10. The method for inspecting a glass container for defects of claim 9, wherein the selected portion is the finish portion of the glass container.
 11. The method for inspecting a glass container for defects of claim 10, wherein the defect is a check.
 12. The method for inspecting a glass container for defects of claim 9, wherein said angle of rotation is a portion of 360 degrees.
 13. The method for inspecting a glass container for defects of claim 12, wherein the plurality of said consecutive selected angles defines 360 degrees.
 14. The method for inspecting a glass container for defects of claim 9, wherein said light source comprises a pair of orthogonal related LED panels.
 15. A method for inspecting a glass container for defects at an inspection station comprising: rotating a selected glass container at the inspection station; illuminating a selected portion of the glass container with a light source so that defects will be highlighted during the rotation of the glass container, the light source having a selected on time followed by a selected off time, wherein the container rotates through a defined angle of rotation while the light source is successively on and off; turning the light source on and off consecutively; imaging the selected illuminated portion of the glass container with a camera including a triggerable imaging portion, the camera having an exposure time at least equal to the time required for the glass container to rotate through the defined angle of rotation; triggering the imaging portion of the camera with a camera switch when the container is at the beginning and the end of the defined angle of rotation so that the camera will image the selected portion of the container, as the glass container rotates through a defined selected angle of rotation, wherein the camera remains open during the entire selected angle of rotation and the camera switch is triggered a plurality of times to define a critical addition of the plurality of images, within the defined angle, for inspection for defects; and configuring a computer to operate the light source switch and the camera switch, the computer being configured to trigger the imaging portion of said camera when the container is at the beginning and end of said defined angle of rotation so that the camera will continuously acquire data of said selected portion of the container, as the glass container rotates through the defined angle of rotation to capture, transfer and record each image when the imaging portion is triggered at the beginning and end of each of said defined angles of rotation, and to perform an addition of a plurality of recorded images, each including a plurality of illuminations for inspection for defects, the plurality of illuminations equal to the number of times the light source switch is operated during the defined angle of rotation.
 16. A method according to claim 15, wherein the selected portion is the finish portion of the glass container.
 17. A method according to claim 15, wherein the defect is a check.
 18. A method according to claim 15, wherein the angle of rotation is a portion of 360 degrees.
 19. A method according to claim 15, wherein the light source comprises a pair of orthogonal related LED panels. 